Modular material tracking system and method

ABSTRACT

A modular material tracking system is provided for tracking material stored on and drawn from a reel using a modular system. The modular material tracking system may include a detection element, digital logic components, location receiver, enclosure, analytic components, interface component, sensor module, and plate module. One or more sensors relative to the reel may detect a position indicative of forward or reverse reel rotation. A processor may analyze signals to count rotations of the reel, which is savable in memory. A battery may provide power. The system may also record the time and location associated with rotations. A method for tracking material stored on and drawn from a reel using a modular material tracking system is also provided.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority from U.S. nonprovisional patentapplication Ser. No. 16/397,883 filed Apr. 29, 2019, U.S. nonprovisionalpatent application Ser. No. 14/810,236 filed Jul. 27, 2015, U.S.provisional patent application Ser. No. 62/029,934 filed Jul. 28, 2014,and U.S. provisional patent application Ser. No. 62/115,486 filed Feb.12, 2015. The foregoing applications are incorporated in their entiretyherein by reference.

FIELD OF THE INVENTION

The present disclosure relates to a modular material tracking system.More particularly, the disclosure relates to tracking material stored onand drawn from a reel using a modular system.

BACKGROUND

Many materials used in construction or the fabrication of products(e.g., wire, cable, tubing, yarn, rope, etc.) are sold from themanufacturer on reels. Distributing materials on reels allows users(e.g., installers, contractors, manufacturers, etc.) to easily obtain adesired amount of the material for a job or task and enables easierstorage and material control. A single reel of material is often usedfor multiple jobs. Many users manually track the usage of material froma reel while completing jobs. Some types of materials include a visuallegend that is printed on the material at given intervals. Tracking theusage of material on reels is often necessary for inventory management,billing, and project planning. Manually tracking the usage of materialfrom a reel requires a significant amount of time and expense andnecessitates a system for recording material use. In addition, manualtracking is subject to significant inaccuracies caused by human error.These inaccuracies contribute to waste and increase project cost.

A variety of material tracking systems have been previously developedfor materials that are distributed from a reel. Some are generally ofthe type that attaches directly to the material, independent of the reeland tracks the movement of the line as it feeds from its container.Taymer International, Inc. (Markham, Ontario, CA) is one example of adistributer of measuring devices that are directly attached to thematerial being distributed. These devices are typically only used in themanufacture of cable because they use a system of complex rollers tomeasure the material as it is spooled out, which makes this solutionexpensive and prone to potential errors. This technical approach alsorequires recalibration of the devices for different material diameter.

Other material tracking systems are used in reel-to-reel audio tapemonitoring, as exemplified in U.S. Pat. No. 5,808,824 to Kaniwa, et al.These systems combine reel to reel tape speed measurements with windingradius calculations to control tape feed through a complex series ofmeasuring devices that are integrated with the machine that reads thetape. The system requires complex sensors on both reels along withcalculations that feed back into the controlling device and requirecomplex manufacturing and assembly. They are permanent components of themachinery and are not used to track inventory. In this system, thedevice uses a ratio between the tension of the tape and the torqueoutput of the reel motors to calculate the radius of an empty take-upspool and then ultimately by tracking the tape fed calculations may bemade to ultimately determine the radius of the working radius of thesupply spool and the length of the fed tape.

Measurement of wire bonding loops is done in semiconductor fabricationas electronic wire is attached to various components as exemplified inU.S. Pat. No. 8,301,841 to Qin. These systems simply calibrate wirepayout based on the timing of a payout mechanism and are not used tomeasure remaining length. They do not measure rotational variables froma spool, reel, or other wire container.

U.S. Pat. No. 6,921,044 to Graber et al shows a device for storing anddetecting the end of a wire as it is unspooled. The device uses the fewwraps of wire closest to the drum to block the magnetic lines of fluxfrom reaching the magnetic sensor mounted outside of the spool. As thelast few wraps of wire no longer block the magnetic flux the sensor willmomentarily pick up that flux once per rotation. If the sensor is hookedto an output source (e.g., Light, siren etc.) the output source willenergize once per rotation informing the user that the wire is about torun out. Among other potential shortcomings, this device does notprovide any advanced warning that the wire will be running out, letalone, provide any inventory management capabilities.

In the fishing gear industry, attempts have been made to developsensor-based systems to track the amount of fishing line let out from afishing reel. For example, U.S. Pat. No. 4,790,492 to Takashi providesfor magnet-based sensor system for measuring and providing the length offishing line paid out or reeled in. This unitary system teachesone-to-one correspondence between sensor sub-system, processor, anddisplay. As such, among other potential shortcomings, the approachdisclosed by the '492 Takashi patent is too expensive for use insimultaneously tracking multiple reels of material.

Therefore, a need exists to solve the deficiencies present in the priorart. What is needed is a system with a detection component to track andrelay the length of material on a reel or spool. What is needed is atracking system to accurately determine material removed from a reel.What is needed is a sensor module and plate module to provide efficientand flexible monitoring of material removed from a reel or spool. Whatis needed is a system to aid in selection of a reel for a deploymentjob. What is needed is a system to centralize information relating tomaterial on various reels. What is needed is a method of trackingmaterial stored on and paid out from one or more reel. What is needed isa method of sensing use characteristics of a reel of material.

SUMMARY

An aspect of the disclosure advantageously provides a system with adetection component to track and relay the length of material on a reelor spool. An aspect of the disclosure advantageously provides a trackingsystem to accurately determine material removed from a reel. An aspectof the disclosure advantageously provides a sensor module and platemodule to provide efficient and flexible monitoring of material removedfrom a reel or spool. An aspect of the disclosure advantageouslyprovides a system to aid in selection of a reel for a deployment job. Anaspect of the disclosure advantageously provides a system to centralizeinformation relating to material on various reels. An aspect of thedisclosure advantageously provides a method of tracking material storedon and paid out from one or more reel. An aspect of the disclosureadvantageously provides a method of sensing use characteristics of areel of material.

According to an embodiment of this disclosure, a system may be providedfor tracking a length of a material wound on a reel, the material havinga known starting length and a known thickness, the reel having a reelcore of known width and known volume, the reel further having reelflanges physically connected to the reel at opposite ends of the reelcore such that the reel flanges rotate with the reel core, the materialbeing wound about the reel core between the reel flanges. The system mayinclude a plate module to be physically installed to the reel includinga reel identification index to identify the reel. The system may includea sensor module removably installed to the plate module. the sensormodule may include a sensor to produce a signal indicative of rotationof the reel. The sensor module may include a sensor module processoroperably receiving the signal from the sensor and counting cumulativeforward rotations of the reel. The sensor module may include a sensormodule memory operably associated with the sensor module processor forstoring memory contents including the cumulative forward rotations ofthe reel. The sensor module may include a radio frequency transmitter tocommunicate at least part of the sensor module memory contents. Thesensor module may include a sensor module battery that may power atleast the sensor module processor, the sensor module memory, the sensor,and the radio frequency transmitter. A remaining length of the materialwound on the reel may be calculated based on at least the cumulativeforward rotations of the reel.

In another aspect, the system may include a docking interface, which mayfurther include a plate docking interface provided by the plate module,and a sensor docking interface provided by the sensor module. The sensordocking interface may be removably received by the plate dockinginterface to provide a docked physical connection. The docked physicalconnection may be selectively disengaged to remove the sensor dockinginterface from the plate docking interface.

In another aspect, the system may include an electronic interface, whichmay further include a plate module electronic interface, and a sensormodule electronic interface. The docked physical connection may alignthe plate module electronic interface and the sensor module electronicinterface to create a docked electronic connection. Electronic signalsmay be selectively communicated via the electronic interface in thedocked electronic connection.

In another aspect, the plate module may be at least partially powered bythe sensor module battery via the electronic interface.

In another aspect, the reel identification index may be communicatedfrom the plate module to the sensor module in via the electronicinterface.

In another aspect, the sensor module may retrieve a length value for thelength of the material included by the reel identified by the reelidentification index. The sensor module may determine the cumulativeforward rotations of the reel occurring subsequent to retrieving thelength value. The sensor module may analyze the cumulative forwardrotations to determine the length of the material drawn from the reel.The sensor module may update the length value identified by the reelidentification index to reflect the length of the material remaining onthe reel after at least part of the material is drawn from the reel.

In another aspect, global memory may be provided that may be accessibleover a network via the radio frequency transmitter to communicate atleast the reel identification index and the length value. One or morelength values may be associated with respectively one or morecorresponding reels and stored by the global memory. At least part ofthe one or more length values stored by the global memory may bedisplayed to a user via an interface.

In another aspect, the sensor module may further include a clock thatoutputs time values. The sensor module memory may store time series dataindicative of the cumulative forward rotations of the reel correlatedwith the time values.

In another aspect, the sensor module may further include a sensorlocation receiver that outputs a geographic position. The sensor modulemay associate an event in which the material is drawn from the reel withthe geographic position at which the material is drawn. The sensormodule may store the geographic position associated with the event inthe sensor module memory.

In another aspect, the sensor module may include a sensor locationreceiver that may output a geographic position and a clock that mayoutput time values. The sensor module memory may store time series dataindicative of the cumulative forward rotations of the reel correlatedwith time values. The sensor module may associate the time series dataindicative of an event in which the material removed from the reel withthe geographic position at which the event occurred. The sensor moduleprocessor may further store the time series data indicative of thegeographic position associated with event in the sensor module memory.

In another aspect, the sensor may detect angular orientation.

In another aspect, the rotations of the reel may be determined using achange in the angular orientation sensed by the sensor.

In another aspect, the sensor may include an accelerometer.

According to an embodiment of this disclosure, a system may be providedfor tracking a length of a material wound on a reel, the material havinga known starting length and a known thickness, the reel having a reelcore of known width and known volume, the reel further having reelflanges physically connected to the reel at opposite ends of the reelcore such that the reel flanges rotate with the reel core, the materialbeing wound about the reel core between the reel flanges. The system mayinclude a plate module, a sensor module, a docking interface, and anelectronic interface. The plate module may be physically installed tothe reel comprising a reel identification index to identify the reel.

The sensor module may be removably installed to the plate module. Thesensor module may include a sensor to detect change in angularorientation and produce a signal indicative of rotation of the reel. Thesensor module may include a sensor module processor operably receivingthe signal from the sensor and counting cumulative forward rotations ofthe reel. The sensor module may include a sensor module memory operablyassociated with the sensor module processor for storing memory contentsincluding the cumulative forward rotations of the reel. The sensormodule may include a sensor module battery powering at least the sensormodule processor, the sensor module memory, and the sensor.

The docking interface may include a plate docking interface provided bythe plate module, and a sensor docking interface provided by the sensormodule. The sensor docking interface may be removably received by theplate docking interface to provide a docked physical connection. Thedocked physical connection may be selectively disengaged to remove thesensor docking interface from the plate docking interface.

The electronic interface may include a plate module electronic interfaceand a sensor module electronic interface. The docked physical connectionmay align the plate module electronic interface and the sensor moduleelectronic interface to create a docked electronic connection.Electronic signals may be selectively communicated via the electronicinterface in the docked electronic connection. The reel identificationindex may be communicated from the plate module to the sensor module viathe electronic interface. A remaining length of the material wound onthe reel may be calculated based on at least the cumulative forwardrotations of the reel, which may be a difference between forwardrotations and reverse rotations.

The sensor module may retrieve a length value for the length of thematerial included by the reel identified by the reel identificationindex. The sensor module may determine the cumulative forward rotationsof the reel occurring subsequent to retrieving the length value. Thesensor module may analyze the cumulative forward rotations to determinethe length of the material drawn from the reel. The sensor module mayupdate the length value identified by the reel identification index toreflect the length of the material remaining on the reel after at leastpart of the material is drawn from the reel.

In another aspect, a global memory may be accessible over a network viaradio frequency transmitter to communicate at least the reelidentification index and the length value. One or more length valuesassociated with respectively one or more corresponding reels may bestored by the global memory. At least part of the one or more lengthvalues stored by the global memory may be displayed to a user via aninterface.

In another aspect, the sensor module may include a clock that may outputtime values. The sensor module memory may store time series dataindicative of the cumulative forward rotations of the reel correlatedwith the time values.

In another aspect, the sensor module may include a sensor locationreceiver that may output a geographic position. The sensor module mayassociate an event in which the material is drawn from the reel with thegeographic position at which the material is drawn. The sensor modulemay store the geographic position associated with the event in thesensor module memory.

According to an embodiment of this disclosure, a method may be providedfor tracking a length of a material wound on a reel, the material havinga known starting length and a known thickness, the reel having a reelcore of known width and known volume, the reel further having reelflanges physically connected to the reel at opposite ends of the reelcore such that the reel flanges rotate with the reel core, the materialbeing wound about the reel core between the reel flanges.

The method may include a) physically installing a plate module to thereel, the plate module including a reel identification index to identifythe reel. The method may include b) removably installing a sensor moduleto the plate module. The method may include c) producing a signalindicative of rotation of the reel using a sensor included by the sensormodule. The method may include d) counting cumulative forward rotationsof the reel via the sensor processor using at least the signal. Themethod may include e) storing memory contents comprising the cumulativeforward rotations of the reel to a sensor module memory operablyassociated with the sensor module processor. The method may include f)calculating a remaining length of the material wound on the reel basedon at least the cumulative forward rotations of the reel. A sensormodule battery selectively may power at least the sensor moduleprocessor, the sensor module memory, and the sensor.

In another aspect, the method may include g) providing a docked physicalconnection via receiving a sensor docking interface by a plate dockinginterface to provide a docked physical connection to provide a dockinginterface. The docked physical connection may be selectively disengagedto remove the sensor docking interface from the plate docking interface.The method may include h) aligning a plate module electronic interfaceand a sensor module electronic interface to create an electronicinterface. Electronic signals may be selectively communicated via theelectronic interface.

In another aspect, the method may include i) retrieving a length valuevia the sensor module for the length of the material included by thereel identified by the reel identification index. The method may includej) determining via the sensor module the cumulative forward rotations ofthe reel occurring subsequent to retrieving the length value. The methodmay include k) analyzing via the sensor module the cumulative forwardrotations to determine the length of the material drawn from the reel.The method may include l) updating via the sensor module the lengthvalue identified by the reel identification index to reflect the lengthof the material remaining on the reel after at least part of thematerial is drawn from the reel.

Terms and expressions used throughout this disclosure are to beinterpreted broadly. Terms are intended to be understood respective tothe definitions provided by this specification. Technical dictionariesand common meanings understood within the applicable art are intended tosupplement these definitions. In instances where no suitable definitioncan be determined from the specification or technical dictionaries, suchterms should be understood according to their plain and common meaning.However, any definitions provided by the specification will govern aboveall other sources.

Various objects, features, aspects, and advantages described by thisdisclosure will become more apparent from the following detaileddescription, along with the accompanying drawings in which like numeralsrepresent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram view of a material tracking system, accordingto an embodiment of this disclosure.

FIG. 2 is a schematic view of a reel in association with abattery-powered measurement sub-system that measures reel rotation andstores associated data, according to an embodiment of this disclosure.

FIG. 3 is an enlarged schematic detailed view of a flange of a reelshowing one embodiment of the placement of a detection element,according to an embodiment of this disclosure.

FIG. 4 is a schematic front view of an embodiment of a first side of afirst PCB of the material tracking system, according to an embodiment ofthis disclosure.

FIG. 5 is a schematic front view of an embodiment of a second side of afirst PCB of the material tracking system, according to an embodiment ofthis disclosure.

FIG. 6 is a schematic front view of an alternative embodiment of a firstside of a first PCB of the material tracking system, according to anembodiment of this disclosure.

FIG. 7 is a schematic front view of an alternative embodiment of asecond side of a first PCB of the material tracking system, according toan embodiment of this disclosure.

FIG. 8 is a schematic front view of an embodiment of a first side of asecond PCB of the material tracking system, according to an embodimentof this disclosure.

FIG. 9 is a schematic front view of an embodiment of a second side of asecond PCB of the material tracking system, according to an embodimentof this disclosure.

FIG. 10 is a schematic front view of an alternate embodiment of a firstside of a second PCB of the material tracking system, according to anembodiment of this disclosure.

FIG. 11 is a schematic front view of an alternate embodiment of a firstside of a second PCB of the material tracking system, according to anembodiment of this disclosure.

FIG. 12 is a diagram view of a reel box containing a reel andmeasurement sub-system, according to an embodiment of this disclosure.

FIG. 13 is a perspective view of a reel in association with ameasurement sub-system including a plate module in a first position,according to an embodiment of this disclosure.

FIG. 14 is a perspective view of a reel in association with ameasurement sub-system including a plate module in a second position,according to an embodiment of this disclosure.

FIG. 15 is a block diagram view of a computerized device upon whichaspects of this disclosure may be operated, according to an embodimentof this disclosure.

FIG. 16 is a flow chart view of an illustrative material sensingoperation, according to an embodiment of this disclosure.

FIG. 17 is a perspective top view of a sensor module, according to anembodiment of this disclosure.

FIG. 18 is a perspective bottom view of a sensor module, according to anembodiment of this disclosure.

FIG. 19 is a perspective top view of sensor module internal components,according to an embodiment of this disclosure.

FIG. 20 is a perspective bottom view of sensor module internalcomponents, according to an embodiment of this disclosure.

FIG. 21 is a perspective top view of a plate module, according to anembodiment of this disclosure.

FIG. 22 is a perspective bottom view of a plate module, according to anembodiment of this disclosure.

FIG. 23 is a perspective view of a sensor module and plate module,according to an embodiment of this disclosure.

FIG. 24 is a perspective view of a sensor module and a plate module,according to an embodiment of this disclosure.

FIG. 25 is a perspective view of a sensor module installed to a platemodule, according to an embodiment of this disclosure.

FIG. 26 is a side elevation view of a sensor module being removablyinstalled to a plate module, according to an embodiment of thisdisclosure.

FIG. 27 is a side elevation view of a sensor module being removablyinstalled to a plate module, according to an embodiment of thisdisclosure.

DETAILED DESCRIPTION

The following disclosure is provided to describe various embodiments ofa modular material tracking system. Skilled artisans will appreciateadditional embodiments and uses of the present invention that extendbeyond the examples of this disclosure. Terms included by any claim areto be interpreted as defined within this disclosure. Singular formsshould be read to contemplate and disclose plural alternatives.Similarly, plural forms should be read to contemplate and disclosesingular alternatives. Conjunctions should be read as inclusive exceptwhere stated otherwise.

Expressions such as “at least one of A, B, and C” should be read topermit any of A, B, or C singularly or in combination with the remainingelements. Additionally, such groups may include multiple instances ofone or more element in that group, which may be included with otherelements of the group. All numbers, measurements, and values are givenas approximations unless expressly stated otherwise.

For the purpose of clearly describing the components and featuresdiscussed throughout this disclosure, some frequently used terms willnow be defined, without limitation. The terms pay off and payout, asused throughout this disclosure, is defined as to allow a cable, rope,or flexible material to be run off a reel, spool, or drum. The termreel, as it is used throughout this disclosure, is defined as arevolvable device upon which something flexible is wound. The termsensor module, as it is used throughout this disclosure, is defined as amodular component including a sensor and communication electronics. Theterm plate module, as it is used throughout this disclosure, is definedas a modular component optionally including electronic components toreceive a sensor module.

Also, terminology used throughout this disclosure is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising” or “having” and variations are inclusive setsand may include additional items. The terms “mounted,” “connected” and“coupled” are used broadly and encompass both direct and indirectmounting, connecting, and coupling. Furthermore, “connected” and“coupled” are not restricted to physical or mechanical connections orcouplings, and can include electrical connections or couplings, whetherdirect or indirect. The term “set” is used broadly to refer to one ormore. Also, electronic communications and notifications may be performedusing direct connections, wireless connections, and other connectionsthat will be appreciated by those of skill in the art. The use of theterm “reel” is used broadly and encompasses a cylinder, frame, or otherdevice that turns on an axis and is used to wind up or pay out amaterial and can include a spool, a bobbin, and/or a roller (which maycollectively be referred to as a “core”). The term “material” includes aproduct of any length having a thickness (e.g., width-depth or diameter)that can be wound onto a spool and distributed by unwinding the reel.Examples of materials include, but are not limited to, bare metal wire,metal wire that contains a covering, flexible pipe, rope, yarn, thread,fabric, metal cable, coaxial cable, fiber optic cable, paper, tape,cellophane, plastic filament, 3D printing material, and the like.

Various aspects of the present disclosure will now be described indetail, without limitation. In the following disclosure, a modularmaterial tracking system will be discussed. Those of skill in the artwill appreciate alternative labeling of the modular material trackingsystem as a material tracking system, spool measuring device, reelsensing and measuring apparatus, pay off sensor and calculator, materialmanagement system, the invention, or other similar names. Similarly,those of skill in the art will appreciate alternative labeling of themodular material tracking system as a material pay off sensingoperation, reel tracking method, payout monitoring and managementoperation, material data analytic and inventory management technique,method, operation, the invention, or other similar names. Skilledreaders should not view the inclusion of any alternative labels aslimiting in any way.

It should also be noted that various hardware and software-baseddevices, as well as various structural components may be utilized toimplement the invention. Furthermore, and as described in subsequentparagraphs, the specific configurations illustrated in the drawings areprovided as examples and embodiments of the invention. Alternativeconfigurations are possible.

Referring now to FIGS. 1-27 , the modular material tracking system willnow be discussed in more detail. The material tracking system mayinclude a material, reel, detection element, digital logic components,battery and power components, transceiver and communication components,location receiver, enclosure, analytic components including one or moreprocessor, interface component, and additional components that will bediscussed in greater detail below. The material tracking system mayoperate one or more of these components interactively with othercomponents to track material stored on and drawn from a reel.

The modular material tracking system may also include a sensor module,plate module, and additional components that will be discussed ingreater detail below. The modular material tracking system may operateone or more of these components interactively with other components fortracking material stored on and drawn from a reel using a modularsystem.

An invention enabled by this disclosure relates to tracking the usage ofmaterials from a reel using a material tracking system. FIG. 1demonstrates a basic configuration of a material tracking system enabledby this disclosure. The system may include, among other components, afirst processor 10 that may contain an input/output (I/O) unit 12, amemory 14 (which may be integral to the first processor 10), and aprocessing unit (CPU) 16, at least one sensor 18, optionally a detectionelement 20, one or more power supply modules (e.g., a coin-type or LiPobattery cells) 22, one or more indicators 26, and one or morecommunications modules, including a first transceiver 28. The indicators26 may, for example, include one of more LEDs and/or a liquid crystaldisplay (“LCD”). In one implementation, the controller 10 may beassociated with a single printed circuit board (“PCB”) that is populatedwith one or more of electrical and electronic components that providepower, operational control, and protection to the material trackingsystem. The memory 14 may include, for example, a read-only memory(“ROM”), a random-access memory (“RAM”), an electrically erasableprogrammable read-only memory (“EEPROM”), or other flash memory. Memory14 may store information regarding the rotation of the reel. Forexample, the memory 14 may contain the total number of forward rotationsof the reel. In an embodiment including a real-time clock and/or alocation receiver, for example a GPS receiver, the memory may also savetime/date and/or locations in association with the reel rotational data.Finally, the memory may also store an identification number that isunique to the reel/material to allow a business to track the materialremaining on one or more of reels substantially simultaneously.

The controller or first processor 10 may be operably connected via firsttransceiver 28 to an external device (e.g., a computer, a smart phone, atablet), which may include a processing unit 16 and user interface 24(i.e., combinations of software and hardware that are operable to, amongother things, calculate the amount of material currently on a reel andactivate the one or more indicators 26 or communicate with the one ormore external devices). The processing unit 16 may be connected to amemory on the external device and may execute software that is capableof being stored in the RAM (e.g., during execution), the ROM (e.g., on agenerally permanent basis), or another non-transitory computer readablemedium such as another memory or a disc.

Software included in some embodiments of the material tracking systemmay be stored in the memory operably associated with the processingunit. The software may include, for example, firmware, one or moreapplications, program data, one or more program modules, and otherexecutable instructions. The processing unit may be configured toretrieve from memory and execute instructions related to the controlprocesses and methods described below, including for example, theinstructions for performing calculations necessary to determine thecurrent amount of material on the reel 30 (see FIG. 2 ).

The PCB may also include, among other components, one or more ofadditional passive and active components such as resistors, capacitors,inductors, integrated circuits, and amplifiers. These components may bearranged and connected to provide one or more of electrical functions tothe PCB including, among other things, filtering, signal conditioning,or voltage regulation. For descriptive purposes, the PCB and theelectrical components populated on the PCB are collectively referred toas the battery-powered measurement sub-system 100 (which may also beknown as the counting chip). Furthermore, in some embodiments, the PCBincludes means for affixing the sub-system 100 to a reel or a reel box.The means for affixing the system can be permanent or removable. In someembodiments, the PCB includes a cover or housing which is affixed to thePCB. The cover or housing can be permanent or, more preferably,removable. Where the reel or reel box is exposed to the elements, thehousing can be waterproof or can contain a gasket or seal to preventwater, dust, or other contaminants from reaching the PCB circuitry.

The user interface 24 may be included to control the material trackingsystem. The user interface may be operably coupled to the firstprocessor 10 to receive or input, for example, physical parameters of agiven reel 30 and/or the material stored on the reel for use in trackingusage of the material. Although shown as being associated with asmartphone that uses soft keys, the user interface 24 may include anycombination of digital and analog input devices required to achieve adesired level of control for the system. For example, the user interface24 can be comprised of a computer having a display and input devices, atouch-screen display, one or more of knobs, dials, switches, buttons,faders, and/or the like.

The power supply module 22 may supply nominal voltages to the materialtracking system. The power supply module 22 may include one or morebatteries or battery packs, and more preferably by one or morerechargeable batteries or battery packs. The power supply modules 22 mayalso be configured to supply lower voltages to operate circuits andcomponents within the material tracking system.

The communication module 28 may send and/or receive signals to and/orfrom one or more separate communication modules. Signals may include,among other components, information, data, serial data, and datapackets. The communication module 28 may be coupled to one or moreseparate communication modules via wires, fiber, and/or wirelessly.Communication via wires and/or fiber can be virtually any appropriatenetwork topology known to those skilled in the art, such as Ethernet.Wireless communication can be any appropriate wireless network topologyknown to those skilled in the art, such as Wi-Fi, Bluetooth, LTE,Zig-Bee, etc.

In some embodiments, the communications module 28 is configured toreceive an input. The input is, for example, a streaming input of datavalues, a data packet, a set of data, etc. The input includes, amongother information, an input identifier (e.g., identification number,reel identification index, etc.) for a reel, one or more of physicalparameters for a reel (e.g., reel width, reel core volume, etc.), aninput identifier (e.g., identification number) for a type of material,data from a sensor 20, and one or more of physical parameters for a typeof material (e.g., material length, material outer diameter, etc.).After the input has been received, the input may be transmitted ortransferred to the processing unit 16. In another embodiment, at leastsome processing may be done locally on a processor locally andoperatively connected to the sensor, without limitation. In someembodiments, the processing unit is configured to retrieve, from thememory, one or more of parameters for a type of material based at leastin part on a received input identifier for a type of material. In otherembodiments, the processing unit is configured to retrieve, from memory,one or more of parameters for a reel based at least in part on areceived input identifier for a reel.

Now turning to FIG. 2 , which shows a common configuration of a reel 30,according to an embodiment of this disclosure. In this embodiment, theend cap 34 can be removable or integrated permanently into the reel 30.The detection element 20 and/or plate module may be coupled to the reel30 and can be removable or permanently attached. In some embodiments,the detection element 20 is coupled to the outer edge of one of theflanges 38 of the reel 30. The battery-powered measurement sub-system100 containing first processor 10 and sensors 18 are attached to the endcap 34 and is placed in such a position to track the rotation of thedetection element 20.

In FIG. 3 , a close-up view of a flange 38 of a reel 30 is shown. Adetection element 20 and/or plate module is shown attached to the outeredge of the flange 38.

When material is removed from or added to the reel, the reel rotates,which causes the detection element 20 to rotate. In this embodiment, thesensor 18 may transmit a signal each time it detects the proximity ofthe detection element 20 (e.g., every time the detection element 20passes the sensor 18). In some embodiments, the signals indicate thecurrent direction of rotation of the reel (e.g., clockwise,counterclockwise). In one embodiment, sensors 18 are magnetic sensors.In alternate embodiments, sensor 18 may be a different type of sensorincluding, for example, a capacitive sensor, a laser sensor, an opticalsensor, an infrared sensor, a touch sensor, accelerometers, etc. In someembodiments, the material tracking system includes one or more ofsensors that are spaced apart. Each sensor 18 in the one or more sensorsmay transmit a signal when the detection element passes. In oneembodiment, the detection element 20 may be a type of magnet (e.g.,neodymium). In alternate embodiments, the detection element 20 is anytype of element appropriate for the type of sensor used in the system.

The first processor 10 may be configured to receive signals from thesensor(s) 18. Upon receiving the signals, the controller 10 maydetermine whether the reel 30 has rotated in a first direction (e.g.,clockwise) or in a second direction (e.g., counterclockwise). In someembodiments, the first processor/controller 10 may receive a separatesignal from each sensor 18 in one or more of sensors and determine therotation direction of the reel 30 based on the order in which thesignals are received. For example, the controller 10 may determine thatthe reel 30 is rotating in a first direction when a signal from a firstsensor 18 a is received before a signal from a second sensor 18 b, andthe controller may determine that the reel 30 is rotating in a seconddirection when the signal from the second sensor 18 b is received beforethe signal from the first sensor 18 a.

The processing unit 16 may be configured to determine a new or updatedvalue for the amount (e.g., length) of material on the reel 30. In someembodiments, the controller 10 may determine the new amount of materialon the reel 30 using the following equations:

$\begin{matrix}{{x_{New} = {x_{CURRENT} - {2\pi\sqrt{\frac{\left( {\left( {{L*\pi*\left( \frac{d}{2} \right)^{2}} + n} \right)\text{/}w} \right)}{\pi}}}}},} & {{Equation}\mspace{14mu} 1} \\{x_{New} = {x_{CURRENT} + {2\pi{\sqrt{\frac{\left( {\left( {{L*\pi*\left( \frac{d}{2} \right)^{2}} + n} \right)\text{/}w} \right)}{\pi}}.}}}} & {{Equation}\mspace{14mu} 2}\end{matrix}$

-   -   Wherein:    -   L=starting length of the material on the reel in inches    -   d=diameter of the material on the reel in inches    -   n=volume of the core of the reel in cubic inches    -   w=width of the reel (i.e., distance between the flanges) in        inches    -   xCURRENT=the current value for the length of the material on the        reel in inches, and    -   xNEW=the new value for the length of the material on the reel in        inches

In this embodiment, the processing unit 16 may use equation 1 when thereel 30 has rotated in the first direction (i.e., material has beenremoved from the reel 30). The processing unit 16 uses equation 2 whenthe reel 30 has rotated in the second direction (i.e., material has beenadded to the reel 30). Use of inches as the unit of measurement inEquations 1 and 2 are provided for exemplary purposes and any commonlyused length unit (e.g., feet, yards, meters, centimeters, etc.) or anyfraction thereof can be used, without limitation. In some embodiments,the above-described parameters of the reel 30 and material are retrievedfrom the memory. In other embodiments, the above-described parameters ofthe reel 30 and material are received via the communication module 28.

After calculating a new or updated value for the amount of material onthe reel 30, the processing unit may transmit an output. The output is,for example, a streaming output of data values, a data packet, a set ofdata, etc. The output can include, among other things, an identifier(e.g., identification number or reel identification index) of the reel30, an identifier (e.g., identification number) of the material, and/orthe current value for the amount of material on the reel 30. This valuecan be, for example, in any commonly used linear measurement with inchesbeing one embodiment.

FIG. 4 shows one embodiment of a first side 40 of a first PCB. In someembodiments, a first side 40 of the first PCB includes, among othercomponents, a first controller 10 and a pair of sensors 18. In someembodiments, the first controller 10, among other operations, receivessignals from the pair of sensors 18 as they track the detection element,transmits signals to a second controller of a second PCB, and performsthe material tracking operations described above.

In some embodiments, a second side 42 of the first PCB includes, amongother components, a power supply module 22 containing a pair ofbatteries 44 and a connector 46, as illustrated in FIG. 5 . Theconnector 46 can be any type of standard connector for a PCB, includingsolid pads, pins, or holes. In one embodiment, solid pads are used asthe connector 46. In some embodiments, the first PCB is coupled to asecond PCB via the connector 46. In some embodiments, the first PCB iscoupled to the end cap 34 during packaging of the material on the reel30. In some embodiments, the first PCB is disposable.

FIG. 6 shows one embodiment of a first side 50 of a second PCB. In someembodiments, a first side 50 of the second PCB includes, among othercomponents, a power supply module 22 and a connector 46. In someembodiments, the power supply module 22 is a rechargeable battery andthus requires a dedicated power connection 48 included with theconnector 46. In other embodiments, the battery may be permanent orfactory replaceable.

FIG. 7 shows a second side 60 of a second PCB. In some embodiments, thesecond side contains a second controller 10, a communication module 28and a connector 46. The connector 46 can be any type of standardconnector for a PCB, including solid pads, pins, or holes. For exemplarypurposes, pins are shown in FIGS. 6 and 7. A dedicated power connection48 for recharging the battery is included in the connector 46. In apreferred embodiment, the communication module 28 is a wirelesstransceiver (e.g., Bluetooth BTLE, Kirkland, Wash.). In someembodiments, the first PCB is coupled to a second PCB via the connector46. In one embodiment, the connector 46 of the second PCB may linkdirectly to the connector of the first PCB. In some embodiments, theconnector 46 of the second PCB may link to the first PCB via wires. Insome embodiments, the first PCB is coupled to the end cap 34 duringpackaging of the material on the reel 30. In some embodiments, thesecond PCB (i.e., first transceiver 28) is removable and can be used onmultiple first PCBs (i.e., battery-powered measurement sub-system 100).In some embodiments, the first PCB 100 may be disposable.

FIG. 8 shows an alternate embodiment of a first side 70 of a first PCB.In some embodiments, a first side 70 of the first PCB includes, amongother components, a power supply 22 and a connector 46. In someembodiments, the power supply module 22 is a pair of batteries 44. Inthis example, the connector 46 comprises one or more of holes for pinconnections. In one embodiment the PCB has a series of openings 72 toaffix the PCB to an end cap. Standard affixing means such as screws,nails or the like can be used in the openings 72 to secure the PCB ontothe end cap.

FIG. 9 shows an alternate embodiment of a second side 80 of a first PCB.In some embodiments, the second side 80 of the first PCB includes, amongother components, a first controller 10, a pair of sensors 18 and aconnector 46. The connector 46 can be any type of standard connector fora PCB, including solid pads, holes, or pins. In this embodiment, theconnector 46 comprises one or more of holes, among other components. Inone embodiment the PCB has a series of openings 72 to affix the PCB toan end cap. Standard affixing means such as screws or nails or the likecan be used in the openings 72 to secure the PCB onto the end cap.

FIG. 10 shows an alternate embodiment of a first side 90 of a secondPCB. This PCB may include, among other components, a user interface 24,an indicator 26, and a power supply module 22. In some embodiments, theuser interface 24 is an LCD screen which displays a number thatrepresents the current amount of material on the reel, in approximatelyreal time. In some embodiments, the user interface 24 displaysinformation about the nature of the material and the reel that has beeninput by a user from a mobile computing platform such as a smart phone,tablet, and/or computer. In some embodiments, the indicator 26 is an LEDwhich activates or deactivates based on the amount of material on thereel. For example, the LED activates when less than 10% of the originalamount of material is left on the reel. In some embodiments, the powersupply module 22 holds a battery (not shown).

FIG. 11 shows an alternate embodiment of a second side 100 of the secondPCB and includes, among other components, a second controller 10, aconnector 46, and a communication module 28. In a preferred embodiment,the communication module 28 is wireless (e.g., Bluetooth, BTLE,Kirkland, Wash.). In some embodiments, the second PCB is coupled to afirst PCB via the connector 46. In some embodiments, the secondcontroller 10, among other operations, receives signals from the firstcontroller of a first PCB, performs the material tracking operationsdescribed above, operates the user interface 24 and indicators 26, andtransmits information to other components wirelessly via thecommunication module 28. In some embodiments, the second PCB isremovably affixed to a reel box by a user after a reel is installed inthe reel box. Means for affixing the second PCB can include any commonmeans such as screws, nails, hook and loop connectors, wire, etc. Insome embodiments, the second PCB is reusable and is used with multiplefirst PCBs.

As illustrated in FIG. 12 , in some embodiments, a second PCB 110 iscoupled to a reel box 112 that contains, among other components, a reel(not shown). In some embodiments, the second PCB 110 is coupled to thereel or reel box 112 during packaging of the material on the reel. In apreferred embodiment, the second PCB is removable from the reel box 112and is used with multiple first PCBs. In some embodiments, the secondPCB is disposable. An opening 114 for the material to be removed fromthe reel box 110 is shown. A slot 116 for the removable second PCB to beconnected to the first PCB (not shown) for up- and down-loading ofinformation is shown. The slot 116 is oriented with the reel box 112 sothat the connectors of the first PCB and second PCB 110 may align.

By way of example, according to an embodiment enabled by thisdisclosure, a first PCB containing magnetic sensors is affixed at adistance of 6 inches from the central axis of a first end cap that issized for a reel of wire (Cat 5 Plenum, Anixter, Glenview, Ill.). Thefirst and second end cap are placed on the reel. A sensor, such as anaccelerometer or magnetic detection element (#8 Screw Neodymium magnet,Applied Magnets, Plano, Tex.) is attached to a flange of the reelopposite from the first end cap. The reel is placed in a reel box andshipped to a user. The user may program a second PCB with the inputidentifier by a laptop computer which sends the information wirelesslyto the transceiver in the second PCB. The user then attaches the secondPCB to the outside of the reel box. As the user retrieves wire from thereel box, the reel rotates and the sensors of the first PCB detect therotation of the detection element. The sensors send a signal to thesecond PCB with the number of rotations which can be a whole number or afractional number. The sensor also detects, tracks, and transmitsreverse rotations as wire is replaced or unused wire is rewound. Thesecond PCB may be loaded with software which performs the calculationsas described above using either Equation 1 for forward rotation (use ofwire) or Equation 2 for reverse rotation (respooling or reloading). Thesecond PCB may then send a signal containing the current amount of wireto the laptop computer for material tracking purposes.

In an alternate example, a first PCB containing optical sensors isaffixed at a distance of 1 foot from the central axis of a first end capthat is sized for a reel of wire (18-02 OAS, Lake Cable 529 Thomas DriveBensenville, Ill.). The first and second end cap are placed on the reel.An optical detection element (Light to digital converter, AMS, StyriaAustria) is placed on a flange of the reel opposite from the first endcap. This is repeated for multiple reels of wire. The reels are shippedto a user. The user programs a second PCB with the input identifier ofeach reel with a smart phone. The smart phone sends the information to awireless transceiver in the first PCB. As the user retrieves wire fromthe reel box, the reel rotates and the sensors of the first PCB detectthe rotation of the detection element. The sensors send a signal to thesmart phone with the input identifier and the number of rotations whichcan be a whole number or a fractional number. The sensor also detects,tracks, and transmits reverse rotations as wire is replaced or unusedwire is rewound.

Now turning to FIGS. 13-14 , and additional embodiment will be describedwithout limitation. FIGS. 13-14 show a common configuration of a reel 30with one or more attached sensors 18, for example, attached to flanges38. In this embodiment, an end cap can be removable or integratedpermanently into the reel 30. The sensor 18 may include an accelerometeror other device capable of detecting an angular orientation. The sensor18 may be operatively connected to a battery-powered sub-system 100,such as the version illustrated in FIG. 1 . In one example, the sensor18 may be communicatively connected to the battery-powered sub-system100 wirelessly, without limitation. Since the position of the reel maybe determined from the angular orientation of the sensor, thisembodiment may advantageously remove the need for separate detectionelements 20 as described along with other embodiments.

Referring now to FIG. 13 , the reel 30 illustrates the sensor 18installed to a reel flange 38. In one embodiment, the sensor may beprovided by a sensor module attached to a plate module installed to thereel. The sensor may indicate an angular orientation, which mayrepresent a starting state for determination of a number of rotations ofthe reel 30. As the reel 30 is rotated, the sensor may be repositionedalong the X and/or Y axis in respect to a Z axis about which the reel 30may be rotated. In one embodiment, the sensor 18 may measure changes inangular orientation about a single X or Y axis. In another embodiment,the sensor 18 may measure changes in angular orientation about both theX and Y axis substantially simultaneously, which may provide a vectorvalue. As the reel 30 is rotated, for example, as material included bythe reel 30 is paid out, the location of the sensor 18 will change,which will change the angular orientation of the sensor 18 with respectto the rotational Z axis of the reel 30. For example, an initiallocation of the sensor 18 may be a location such as shown in FIG. 13 andthe subsequent location of the sensor 18 may be a location such as shownin FIG. 14 .

The frequency at which the sensor 18 may determine angular orientationmay be set for a given application, precision, and desired quantity ofdata produced. In one example, provided without limitation, anaccelerometer included in a sensor 18 may determine angular orientationat a rate of 40 Hz. Sensor data may be included in local storage and mayprocessed locally to determine rotations and total amounts paid out.This initial processing being performed locally may advantageouslyreduce the amount of data having to be transmitted from local memory toglobal memory. For example, local processing may reduce 40 Hz of sensedraw angular orientation data to 1 Hz of processed data indicative ofmaterial paid out, rotational direction, material remaining on the reel,and/or other information. This embodiment may additionally reduce theneed for a large local memory, for example and without limitation, toquantities around 4 megabytes, advantageously reducing the cost ofmaterials to produce a system enabled by this embodiment. Alternatively,the raw data read by the sensor 18 may be transmitted to global memoryfor remote processing and analytics.

Data may be communicated via transceiver, for example, via Wi-Fi, 4G,5G, cellular data, or networking protocols that would be appreciated bythose of skill in the art. In some embodiments, a gateway may beprovided to bridge communication protocols between a global network,such as an intranet and/or internet, and a local wireless networkbetween the gateway and the sensor 18.

In this embodiment, the sensor 18 may report its angular orientation fora given positional location, which may indicate a change from apreviously reported angular orientation. The change in angularorientation may be analyzed to determine a rate of change, direction ofchange, number of rotations, and other information relating to thewinding or paying out of material included by the reel 30. A locationreceiver may be included with the sensor to determine a geographicposition of the reel 30 to assist with determining whether material isbeing paid out or whether the reel is simply being rolled fortransportation or relocation. The location receiver may use GPS,cellular triangulation, MM waves, ultrawideband tracking, and otherlocation determining techniques to determine a location of a spool orreel. The reading of values from the sensor 18 may additionally beselectable between on and off states manually and/or dynamically from anoperator and/or controller.

By including an accelerometer in the sensor, this embodimentadvantageously removes the need for additional sensors to be included ina box housing the reel. The sensor may include features to assist withidentification, for example, RFID, near-field communication (NFC),Bluetooth, and/or other protocols that would be appreciated by those ofskill in the art. For example, the unique identification number may becommunicated via one or more of the above features to assist withidentification of a reel. Wireless data may be transmitted from thedevice including the sensor via transceiver and/or radio, which mayinclude and/or interface with an antenna, for example, a PCB antenna,chip antenna, external antenna, and/or another antenna.

In an embodiment, a processing unit 16 on a smart phone (or otherportable computing device) may be loaded with an application whichperforms the calculations as described above using Equation 1 forforward rotation (use of wire), or Equation 2 for reverse rotation(respooling or reloading), and/or another equation. The smart phoneapplication may further provide a spreadsheet on the smart phone screencontaining the current amount of wire for each reel by using the uniqueidentification number stored in the memory associated with each reel.This information may then be uploaded at a preferred interval (e.g.,per-second, per-minute, hourly, daily, weekly, monthly) to software on adesktop computer in the user's inventory control office.

The basic information regarding the amount of material, time/date,location, and/or other information obtained from the battery-poweredmeasurement sub-system 100 may be manipulated by the processing unit 16to determine a variety of potentially useful management metrics. Forexample, the data may easily be mathematically and logically organizedand reorganized to determine: (a) the date and time of each pull; (b)location of each pull; (c) accurate billing based on time and materialsactually expended at a specific job; (d) reducing overhead andminimizing wasted materials; and (e) maximize installer efficiency.Information may be sharable or saleable to distributors, manufacturers,and other parties to increase efficiencies and better anticipate marketdemands.

The processing of data may be adjusted to increase accuracy of thecalculations, which may be performed locally and/or over a networkedcomputing device. Feedback may be provided to the system regardingcalculated payout rates, actual material paid out, margins of error,conditions of the payout, and other factors to improve the accuracy ofthe system. Calculations may be manipulated through the introduction andalteration of correction factors. For the purpose of this disclosure, acorrection factor is intended to include constants, variables, scalarvalues, calibrations, formulae, and other mathematical operations tomanipulate the calculations performed on sensed data to determine usablevalues and information. For example, a correction factor may be appliedto account for the width of cable on a reel, whether the cable is asingle conductor, tightness of spooling, respooled material, and otherfactors.

The feedback may be substantially automatically calculated through useof the system, manually entered, dynamically learned, and/or otherwisereceived. In one embodiment, a machine learning approach may be used toadjust correction factors based on iterations between multipleoperations. For example, machine learning can be used to determine aproposed correction factor, check whether the correction factor improvedaccuracy of the calculation, and adjust the predictive weight of usingthe correction factor based on the results. The machine learningoperation may be initially based on a rule set. This iterative processcan be substantially continually repeated, allowing refinement of thecalculation accuracy. The feedback may additionally be used with a faulttree, which may use data science to learn and improve initialization forvarious operating conditions. Sensors may be associated with informationregarding material on a reel to further increase the likelihood ofchoosing proper correction factors and other variables associated withthe material to improve accuracy.

In particular, the system allows an installer, his supervisor, supplyordering clerks to see the length wire remaining in each reel, spool,box, and/or other material-holding apparatus on site and at the office.For an installer on-site, the information means substantially limitingwasted labor time guessing whether a spool will make it to the end ofthe run; or risking a time exhausting repull. On the other hand, asupervisor would be able to see how many feet of cable have beeninstalled versus the amount of cable use projected for a given job.

In one embodiment, the interface and operations performed by theprocessor may be updatable. For example, electronic components relatingto the sensor and sub-system may be updated via firmware flashing,register editing, configuration files, over-the-air updates, securityupdates, and other manipulation of data that could affect operation. Thesensor and/or additional components may include one or more expansionports, which may provide additional functionality through supplementalhardware. Solder contacts may additionally be provided for theinstallation of hardware, for example, a radio or antenna.

Scrapping cable is leakage that most utilities and installers just dealwith right now because of the labor cost to sort it out. A tool andsystem enabled by this disclosure can advantageously and substantiallyseamlessly provide actionable inventory data that allows users to use alarge portion of their cable efficiently. In view of the functionalityof the present system, the remaining inventory after a job is completemay be put into ‘My Random Lengths Inventory’ these random lengths willbe easily searchable for use at future job sites.

Additionally, reels may be selected such that an amount remaining aftera job is a usable quantity that can be used on a future job. Trends maybe determined to assist with efficiently ordering cable and wirequantities most likely to be use substantially completely. For example,historic data on how much cable was pulled at which location on whichday may be used to assist in spotting trends related to issues with jobtypes or indicate which installers are most efficient.

The enclosure will now be discussed in greater detail. In oneembodiment, at least part of the sub-system 100 may be included in anenclosure. The enclosure may include seals, liners, and/or otherfeatures to minimize or prevent the introduction of moisture, dirt, anddust into an interior volume encompassed by the enclosure. The enclosuremay be made of various materials, including plastics, metals, wood, andother materials that will be appreciated by skilled artisans. Theenclosure may be configured such that it may be installed in asubstantially flush orientation with the reel and/or reel flange. Theenclosure may include an antenna operatively connectable to a radio ortransceiver. The sensor may include an expansion port, which may beaccessible by the enclosure.

Referring now to FIG. 15 , an illustrative computerized device will bediscussed, without limitation. Various aspects and functions describedin accord with the present disclosure may be implemented as hardware orsoftware on one or more illustrative computerized devices 1500 or othercomputerized devices. There are many examples of illustrativecomputerized devices 1500 currently in use that may be suitable forimplementing various aspects of the present disclosure. Some examplesinclude, among others, network appliances, personal computers,workstations, mainframes, networked clients, servers, media servers,application servers, database servers and web servers. Other examples ofillustrative computerized devices 1500 may include mobile computingdevices, cellular phones, smartphones, tablets, video game devices,personal digital assistants, network equipment, devices involved incommerce such as point of sale equipment and systems, such as handheldscanners, magnetic stripe readers, bar code scanners and theirassociated illustrative computerized device 1500, among others.Additionally, aspects in accord with the present disclosure may belocated on a single illustrative computerized device 1500 or may bedistributed among one or more illustrative computerized devices 1500connected to one or more communication networks.

For example, various aspects and functions may be distributed among oneor more illustrative computerized devices 1500 configured to provide aservice to one or more client computers, or to perform an overall taskas part of a distributed system. Additionally, aspects may be performedon a client-server or multi-tier system that includes componentsdistributed among one or more server systems that perform variousfunctions. Thus, the disclosure is not limited to executing on anyparticular system or group of systems. Further, aspects may beimplemented in software, hardware or firmware, or any combinationthereof. Thus, aspects in accord with the present disclosure may beimplemented within methods, acts, systems, system elements andcomponents using a variety of hardware and software configurations, andthe disclosure is not limited to any particular distributedarchitecture, network, or communication protocol.

FIG. 15 shows a block diagram of an illustrative computerized device1500, in which various aspects and functions in accord with the presentdisclosure may be practiced. The illustrative computerized device 1500may include one or more illustrative computerized devices 1500. Theillustrative computerized devices 1500 included by the illustrativecomputerized device may be interconnected by, and may exchange datathrough, a communication network 1508. Data may be communicated via theillustrative computerized device using a wireless and/or wired networkconnection.

Network 1508 may include any communication network through whichillustrative computerized devices 1500 may exchange data. To exchangedata via network 1508, systems and/or components of the illustrativecomputerized device 1500 and the network 1508 may use various methods,protocols and standards including, among others, Ethernet, Wi-Fi,Bluetooth, TCP/IP, UDP, HTTP, FTP, SNMP, SMS, MMS, SS7, JSON, XML, REST,SOAP, RMI, DCOM, and/or Web Services, without limitation. To ensure datatransfer is secure, the systems and/or modules of the illustrativecomputerized device 1500 may transmit data via the network 1508 using avariety of security measures including TSL, SSL, or VPN, among othersecurity techniques. The illustrative computerized device 1500 mayinclude any number of illustrative computerized devices 1500 and/orcomponents, which may be networked using virtually any medium andcommunication protocol or combination of protocols.

Various aspects and functions in accord with the present disclosure maybe implemented as specialized hardware or software executing in one ormore illustrative computerized devices 1500, including an illustrativecomputerized device 1500 shown in FIG. 15 . As depicted, theillustrative computerized device 1500 may include a processor 1510,memory 1512, a bus 1514 or other internal communication system, aninput/output (I/O) interface 1516, a storage system 1518, and/or anetwork communication device 1520. Additional devices 1522 may beselectively connected to the computerized device via the bus 1514.Processor 1510, which may include one or more microprocessors or othertypes of controllers, can perform a series of instructions that resultin manipulated data. Processor 1510 may be a commercially availableprocessor such as an ARM, x86, Intel Core, Intel Pentium, MotorolaPowerPC, SGI MIPS, Sun UltraSPARC, or Hewlett-Packard PA-RISC processor,but may be any type of processor or controller as many other processorsand controllers are available. As shown, processor 1510 may be connectedto other system elements, including a memory 1512, by bus 1514.

The illustrative computerized device 1500 may also include a networkcommunication device 1520. The network communication device 1520 mayreceive data from other components of the computerized device to becommunicated with servers 1532, databases 1534, smart phones 1536,and/or other computerized devices 1538 via network 1508. Thecommunication of data may optionally be performed wirelessly. Morespecifically, without limitation, the network communication device 1520may communicate and relay information from one or more components of theillustrative computerized device 1500, or other devices and/orcomponents connected to the computerized device 1500, to additionalconnected devices 1532, 1534, 1536, and/or 1538. Connected devices areintended to include, without limitation, data servers, additionalcomputerized devices, mobile computing devices, smart phones, tabletcomputers, and other electronic devices that may communicate digitallywith another device. In one example, the illustrative computerizeddevice 1500 may be used as a server to analyze and communicate databetween connected devices.

The illustrative computerized device 1500 may communicate with one ormore connected devices via communications network 1508. The computerizeddevice 1500 may communicate over the network 1508 by using its networkcommunication device 1520. More specifically, the network communicationdevice 1520 of the computerized device 1500 may communicate with thenetwork communication devices or network controllers of the connecteddevices. The network 1508 may be, for example, the internet. As anotherexample, the network 1508 may be a WLAN. However, skilled artisans willappreciate additional networks to be included within the scope of thisdisclosure, such as intranets, local area networks, wide area networks,peer-to-peer networks, and various other network formats. Additionally,the illustrative computerized device 1500 and/or connected devices 1532,1534, 1536, and/or 1538 may communicate over the network 1508 via wired,wireless, or other connection, without limitation.

Memory 1512 may be used for storing programs and/or data duringoperation of the illustrative computerized device 1500. Thus, memory1512 may be a relatively high performance, volatile, random accessmemory such as a dynamic random-access memory (DRAM) or static memory(SRAM). However, memory 1512 may include any device for storing data,such as a disk drive or other non-volatile storage device. Variousembodiments in accord with the present disclosure can organize memory1512 into particularized and, in some cases, unique structures toperform the aspects and functions of this disclosure.

Components of illustrative computerized device 1500 may be coupled by aninterconnection element such as bus 1514. Bus 1514 may include one ormore physical busses (for example, busses between components that areintegrated within a same machine) but may include any communicationcoupling between system elements including specialized or standardcomputing bus technologies such as USB, Thunderbolt, SATA, FireWire,IDE, SCSI, PCI, and InfiniBand. Thus, bus 1514 may enable communications(for example, data and instructions) to be exchanged between systemcomponents of the illustrative computerized device 1500.

The illustrative computerized device 1500 also may include one or moreinterface devices 1516 such as input devices, output devices andcombination input/output devices. Interface devices 1516 may receiveinput or provide output. More particularly, output devices may renderinformation for external presentation. Input devices may acceptinformation from external sources. Examples of interface devicesinclude, among others, keyboards, bar code scanners, mouse devices,trackballs, magnetic strip readers, microphones, touch screens, printingdevices, display screens, speakers, network interface cards, etc. Theinterface devices 1516 allow the illustrative computerized device 1500to exchange information and communicate with external entities, such asusers and other systems.

Storage system 1518 may include a computer readable and writeablenonvolatile storage medium in which instructions can be stored thatdefine a program to be executed by the processor. Storage system 1518also may include information that is recorded, on or in, the medium, andthis information may be processed by the program. More specifically, theinformation may be stored in one or more data structures specificallyconfigured to conserve storage space or increase data exchangeperformance. The instructions may be persistently stored as encoded bitsor signals, and the instructions may cause a processor to perform any ofthe functions described by the encoded bits or signals. The medium may,for example, be optical disk, magnetic disk, or flash memory, amongothers. In operation, processor 1510 or some other controller may causedata to be read from the nonvolatile recording medium into anothermemory, such as the memory 1512, that allows for faster access to theinformation by the processor than does the storage medium included inthe storage system 1518. The memory may be located in storage system1518 or in memory 1512. Processor 1510 may manipulate the data withinmemory 1512, and then copy the data to the medium associated with thestorage system 1518 after processing is completed. A variety ofcomponents may manage data movement between the medium and integratedcircuit memory element and does not limit the disclosure. Further, thedisclosure is not limited to a particular memory system or storagesystem.

Although the above-described illustrative computerized device is shownby way of example as one type of illustrative computerized device uponwhich various aspects and functions in accord with the presentdisclosure may be practiced, aspects of the disclosure are not limitedto being implemented on the illustrative computerized device 1500 asshown in FIG. 15 . Various aspects and functions in accord with thepresent disclosure may be practiced on one or more computers havingcomponents other than that shown in FIG. 15 . For instance, theillustrative computerized device 1500 may include specially programmed,special-purpose hardware, such as for example, an application-specificintegrated circuit (ASIC) tailored to perform a particular operationdisclosed in this example. While another embodiment may performessentially the same function using several general-purpose computingdevices running Windows, Linux, Unix, Android, iOS, MAC OS X, or otheroperating systems on the aforementioned processors and/or specializedcomputing devices running proprietary hardware and operating systems.

The illustrative computerized device 1500 may include an operatingsystem that manages at least a portion of the hardware elements includedin illustrative computerized device 1500. A processor or controller,such as processor 1510, may execute an operating system which may be,among others, an operating system, one of the above-mentioned operatingsystems, one of many Linux-based operating system distributions, a UNIXoperating system, or another operating system that would be apparent toskilled artisans. Many other operating systems may be used, andembodiments are not limited to any particular operating system.

The processor and operating system may work together to define acomputing platform for which application programs in high-levelprogramming languages may be written. These component applications maybe executable, intermediate (for example, C# or JAVA bytecode) orinterpreted code which communicate over a communication network (forexample, the Internet) using a communication protocol (for example,TCP/IP). Similarly, aspects in accord with the present disclosure may beimplemented using an object-oriented programming language, such as JAVA,C, C++, C#, Python, PHP, Visual Basic .NET, JavaScript, Perl, Ruby,Delphi/Object Pascal, Visual Basic, Objective-C, Swift, MATLAB, PL/SQL,Open Edge ABL, R, Fortran, or other languages that would be apparent toskilled artisans. Other object-oriented programming languages may alsobe used. Alternatively, assembly, procedural, scripting, or logicalprogramming languages may be used.

Additionally, various aspects and functions in accord with the presentdisclosure may be implemented in a non-programmed environment (forexample, documents created in HTML5, HTML, XML, CSS, JavaScript, orother format that, when viewed in a window of a browser program, renderaspects of a graphical-user interface, or perform other functions).Further, various embodiments in accord with the present disclosure maybe implemented as programmed or non-programmed elements, or anycombination thereof. For example, a web page may be implemented usingHTML while a data object called from within the web page may be writtenin C++. Thus, the disclosure is not limited to a specific programminglanguage and any suitable programming language could also be used.

An illustrative computerized device included within an embodiment mayperform functions outside the scope of the disclosure. For instance,aspects of the system may be implemented using an existing commercialproduct, such as, for example, Database Management Systems such as a SQLServer available from Microsoft of Redmond, Wash., Oracle Database orMySQL from Oracle of Redwood City, Calif., or integration software suchas WebSphere middleware from IBM of Armonk, N.Y.

In operation, a method may be provided for tracking material stored onand drawn from a reel using a modular system. Those of skill in the artwill appreciate that the following methods are provided to illustrate anembodiment of the disclosure and should not be viewed as limiting thedisclosure to only those methods or aspects. Skilled artisans willappreciate additional methods within the scope and spirit of thedisclosure for performing the operations provided by the examples belowafter having the benefit of this disclosure. Such additional methods areintended to be included by this disclosure.

Referring now to flowchart 1600 of FIG. 16 , an example method for anillustrative material sensing operation will be described, for exampleas may be performed by a sensor module, without limitation. Startingwith Block 1602, the operation may begin by reading angular orientationvalues of a sensor including an accelerometer, which may include Xand/or Y coordinates. (Block 1604). The angular orientation values maybe compared with the last reading taken by the sensor. (Block 1606). Itmay then be determined at Block 1610 whether a significant change inreadings is detected.

If a significant change in readings is not detected in the operation ofBlock 1610, the operation may proceed to store the current X and/or Ycoordinates as the new last reading. (Block 1644). The operation maythen sleep for a period. (Block 1646). The sleep period may be definedmanually, adjusted dynamically, or be substantially automaticallyadjusted based on analyzing feedback. The operation may then return toBlock 1064 and again read the values from the sensor.

If a significant change in readings is detected in the operation ofBlock 1610, the vector direction and amplitude may be determined usingthe X and/or Y coordinates. (Block 1612). The operation may then comparevectors stored in an array of multiple elements. (Block 1614). It maythen be determined at Block 1620 whether enough vectors exist in thearray to make a decision.

If insufficient vectors are determined to exist during the operation ofBlock 1620, the current vector may be stored in an array, such as a“first in, first out” (FIFO) array of multiple numbered elements. (Block1642). The operation may then continue to Block 1644 to proceed asdiscussed above.

If sufficient vectors are determined to exist during the operation ofBlock 1620, it may then determine whether the reel is in a spinning orrolling state. (Block 1630). If it is determined at Block 1630 that thereel is in a rolling state, the operation may continue to Block 1642 toproceed as discussed above.

If it is determined at Block 1630 that the reel is spinning, theoperation may calculate the change in angular orientation since the lastX and/or Y reading. (Block 1652). An algorithm may then be used tocalculate the length of material removed from the reel based on thechange in angular orientation as the reel is spun. (Block 1654). Thecurrent reel length may then be stored to memory. (Block 1656). Theoperation may then continue to Block 1642 and proceed as discussedabove.

In additional embodiments of this disclosure, features of the sensordevice may be provided over multiple modules. FIGS. 17-27 illustrateaspects of these additional embodiments and should be considered alongwith the discussion provided throughout this disclosure. For example,features of the sensor device provided by this disclosure may bedistributed between a sensor module and a plate module. And thisembodiment, one that practices an invention enabled by this disclosuremay advantageously reduce the amount of costly electronic componentsrequired for sensing and processing of sensed information to only anumber of necessary sensor modules needed for an anticipated load ofsimultaneous jobs. A less expensive plate module may be installed to oneor more reels or other objects to be tracked, allowing for receipt ofthe sensor module to enable the full scope of operability while trackingthe removal of a material for a job.

The plate module will now be discussed in greater detail. FIGS. 21-27highlight examples of the plate module, which may also be shown in otherfigures. The plate module 2100 may advantageously provide a relativelyinexpensive device that may be installed to a reel and/or another objectto be tracked. For example, the plate module 2100 may be installed to areel using screws such that, while removal is not made impossible, theplate module 2100 is intended to remain with the reel for as long as itwill be tracked, such as when material is paid off from the reel andwhile the reel is in storage. In at least one embodiment, the platemodule 2100 may be installed to a reel, spool, or other location atvirtually any point in the supply chain.

In an example where the plate module 2100 is installed to a reel ofcable or material, the plate module may be installed at the point ofmanufacture of the reel, at the cable manufacturer that installs thecable to a reel, at a distributor that sells a reel, at a utility orother company that uses the reel, at the job site where material will bedrawn from the reel, and/or at other steps along the supply chain. Dataprovided by and/or associated with a plate module may carry metadata andother information relating to the reel throughout the supply chain,which may be identifiable via a unique reel identification indexprovided by the plate module and associated with the reel. The reelidentification index may be associated with a reel before the sensormodule is added to the plate module. Metadata and other information mayinclude, without limitation, length of cable, location, GPS coordinates,cable type, timestamp of last usage, duration of usage, and otherinformation that would be appreciated by those of skill in the art afterhaving the benefit of this disclosure.

The plate module 2100 may include plate module electronic componentsthat may assist with identifying the reel onto which the plate module2100 is attached. The plate module 2100 may additionally include a platemodule docking interface 2154 to receive a sensor module 2200, whichwill be discussed in greater detail below.

A plate module 2100 may include plate module electronic componentsinstalled within a plate module enclosure 2150. The plate moduleelectronic components may include various features to provide a reelidentification index so that an operator may identify and trackinventory and usage as it relates to each reel. For example, the platemodule 2100 may include a printed serial number, RFID identificationchip and antenna, QR code, NFC communication, passive electronicidentification components, active electronic identification components,and/or other components that will be appreciated by a person of skill inthe art after having the benefit of this disclosure.

In some embodiments, the plate module 2100 may additionally include aplate module controller and/or plate module processor, which may beoperatively connected to plate module memory and/or a digital platemodule storage medium. In one embodiment, the plate module may include aplate module battery that may deliver electrical power to one or moreplate module electronic components, without limitation. In anotherembodiment, the plate module electronic components may be configured tooperate substantially passively. In this passive configuration, theplate module electronic components may draw power from a connecteddevice, such as a sensor module 2200 that may be connected to the platemodule 2100. One or more of the plate module electronic components mayor operate passively, for example such as with RFID identificationfeatures.

In an embodiment that includes a radio-frequency identification (RFID)feature, the plate module 2100 may include a RFID circuit and/or an RFIDantenna. Those who are skilled in the art will appreciate RFIDtechnology and the process through which RFID operates. In the interestof clearly describing an invention that may be enabled by thisdisclosure, an RFID feature may advantageously allow digitalidentification of a plate module 2100 when brought within sufficientproximity to an additional component, such as a sensor module 2200, afield-deployed scanner device, a computer application coupled with aRFID sensor, or other components, without limitation.

In an embodiment that includes a near-field communication (NFC)identification feature, the plate module 2100 may include an NFC circuitand/or an NFC antenna. Those who are skilled in the art will appreciateNFC technology and the process through which NFC operates. In theinterest of clearly describing an invention that may be enabled by thisdisclosure, an NFC feature may advantageously allow digitalidentification of a plate module 2100 when brought within sufficientproximity to an additional component, such as a sensor module 2200, afield-deployed scanner device, a computer application coupled with a NFCsensor, or other components, without limitation.

The plate module electronic components included by the plate module 2100may be integrated into a circuit board. For example, a circuit boardprovided by the plate module 2100 may include a plate module processor,plate module memory, plate module communication device, and/or otherelectronic features that would be appreciated by a person of skill inthe art after having the benefit of this disclosure. In one embodiment,the circuit board may include electronics to provide power management,which may be operatively connected to a plate module battery, withoutlimitation. In other embodiments, plate module power circuitry and/or aplate nodule battery may be omitted such that the plate module 2100 mayoperate substantially passively.

The plate module enclosure 2150 may include one or more features tofacilitate installation to a reel and provide capacity to receive anadditional component, such as a sensor module 2200. For example, theplate module enclosure 2150 may include a plate module enclosure memberinstallation aperture 2152 to facilitate installation of the platemodule 2100 to a reel or other object. For example, screws or otherattachment hardware may be passed through the plate module enclosuremember installation aperture 2152 to be received by the material of thereel or other object to which the plate module 2100 may be installed.

The plate module enclosure 2150 may additionally include a plate moduledocking interface 2154 to facilitate the removable installation of asensor module 2200 or other device to the plate module 2100, as will beappreciated by a person of skill in the art after having the benefit ofthis disclosure. For example, the plate module docking interface 2154may include one or more extensions of material to receive the sensormodule 2200 or another component. The distal end of these extensions mayinclude additional material such as to hold a corresponding channelprovided by the sensor module 2200 when installed to the plate module2100. In one embodiment, the plate module docking interface 2154 may beprovided such that it may be received by a sensor module dockinginterface 2254, such as may be provided in a slide-and-lock dockingoperation illustrated in FIGS. 26-27 .

The plate module enclosure 2150 may additionally include features toassist with maintaining the installation status of the sensor module2200, for example, as may be provided by a plate module docking clip2156. In this example, once a sensor module 2200 is installed to theplate module 2100, the sensor module 2200 may be held in place at leastpartially by the plate module docking clip 2156. To remove the sensormodule 2200 from the plate module 2100, an operator may engage the platemodule docking clip 2156 such that the sensor module 2200 may beremovable from its docked position on the plate module 2100. Skilledartisans will appreciate additional locking mechanisms that may beincluded by the plate module 2100 and/or the sensor module 2200 afterhaving the benefit of this disclosure, which are also intended to beincluded within the scope and spirit of this disclosure.

In one embodiment, the plate module enclosure 2150 may be provided inmultiple members. For example, the plate module enclosure 2150 may beprovided by a bottom plate module enclosure member 2160 and a top platemodule enclosure member 2180. For example, the top plate moduleenclosure member 2180 may be installable to the bottom plate moduleenclosure member 2160 to provide a substantially unitary plate moduleenclosure 2150. An example of a plate module enclosure 2150 includingmultiple members will be discussed below without limitation.

The complete plate module enclosure 2150 may include a bottom platemodule enclosure member 2160. In one example, the bottom plate moduleenclosure member 2160 may be constructed having a bottom plate moduleenclosure member body featuring material extending from a bottom platemodule enclosure member outer surface to a bottom plate module enclosuremember inner surface. One or more apertures may be provided as passingthrough the bottom plate module enclosure member body, for example tofacilitate installation of the plate module 2100 to a reel, connectionof the bottom plate module enclosure member 2160 to the top plate moduleenclosure member 2180, and/or other connections that would beappreciated by those of skill in the art after having the benefit ofthis disclosure.

For example, one or more plate module enclosure member installationapertures 2152 may be provided by the bottom plate module enclosure 2150to facilitate installation of the plate module 2100 to a reel or otherobject. In this example, a screw or other attachment hardware may bepassed through a plate module enclosure member installation aperture2152 from the bottom plate module enclosure member inner surface,through the bottom plate module enclosure member body, and exiting thebottom plate module enclosure member outer surface to be received by thereel or an installation interface provided by the reel.

In another example, one or more bottom plate module enclosure memberconnection apertures 2168 may be provided by the bottom plate moduleenclosure member 2160 to facilitate installation of the bottom platemodule enclosure member 2160 to the top plate module enclosure member2180. In this example, the bottom plate module enclosure memberconnection apertures 2168 may be aligned with corresponding top platemodule enclosure member connection receptacles. In this example, a screwor other hardware may be passed through the bottom plate moduleenclosure member connection aperture 2168 from a bottom plate moduleenclosure member outer surface, through the bottom plate moduleenclosure member body, and exiting the bottom plate module enclosuremember inner surface such that it may be received by a top plate moduleenclosure member connection receptacle, without limitation.

The plate module enclosure 2150 may include a top plate module enclosuremember 2180. In one example, the top plate module enclosure member 2180may be constructed having a top plate module enclosure member bodyfeaturing material extending from a top plate module enclosure memberouter surface to a top plate module enclosure member inner surface. Oneor more apertures may be provided passing through the top plate moduleenclosure member body, for example to facilitate installation of theplate module 2100 to a reel and/or other connections that would beappreciated by those of skill in the art after having the benefit ofthis disclosure. Additionally, one or more top plate module enclosuremember connection receptacles may be provided to receive a screw orother hardware passed through the bottom plate module enclosure memberconnection aperture 2168, for example to facilitate connection of thebottom plate module enclosure member 2160 to the top plate moduleenclosure member 2180 and/or other connections that would be appreciatedby those of skill in the art after having the benefit of thisdisclosure.

For example, one or more plate module enclosure member installationapertures 2152 may be provided by the top plate module enclosure 2150 tofacilitate installation of the plate module 2100 to a reel or otherobject. In this example, a screw or other attachment hardware may bepassed through a top plate module enclosure member installation aperture2152 from the top plate module enclosure member outer surface, throughthe top plate module enclosure member body, exiting the top plate moduleenclosure member inner surface, and passing through the bottom platemodule enclosure member 2160, to be received by the reel or aninstallation interface provided by the reel.

In another example, one or more top plate module enclosure memberconnection receptacles may be provided by the top plate module enclosuremember 2180 to facilitate installation of the bottom plate moduleenclosure member 2160 to the top plate module enclosure member 2180. Inthis example, the bottom plate module enclosure member connectionapertures 2168 may be aligned with corresponding top plate moduleenclosure member connection receptacles. In this example, a screw orother hardware may be passed through the bottom plate module enclosuremember connection aperture 2168, such that it may be received by a topplate module enclosure member connection receptacle through the topplate module enclosure member outer surface, without limitation. Thoseof skill in the art will appreciate additional arrangements ofconnection apertures and connection receptacles, for example wherein thetop plate module enclosure member 2180 include top plate moduleenclosure member 2180 connection apertures and the bottom plate moduleenclosure member includes bottom plate module enclosure memberconnection receptacles, without limitation.

The sensor module will now be discussed in greater detail. FIGS. 17-20and 23-27 highlight examples of the sensor module, which may also beshown in other figures. The sensor module may include various electroniccomponents to assist with the detection of an event, such as materialbeing drawn from a real. For example, the sensor module may include asensor, a sensor module processor, sensor module memory, radio frequencytransmitter, sensor module battery, and/or other components that wouldbe appreciated by a person of skill in the art after having the benefitof this disclosure. In one embodiment, the sensor module processor,sensor module memory, radio frequency transmitter, and/or othercomponents may be included by a sensor module circuit board 2210, whichmay also be referred to as a sensor module PCB, without limitation.

When operated, the sensor module 2200 may assist with tracking a lengthof a material wound on a reel, the material having a known startinglength and a known thickness, the reel having a reel core of known widthand known volume, the reel further having reel flanges physicallyconnected to the reel at opposite ends of the reel core such that thereel flanges rotate with the reel core, and the material being woundabout the reel core between the reel flanges. This and other informationabout the reel may be retrieved associated with a reel identificationindex, a plate module 2100, and/or another identifier. Information suchas provided in the example above may be retrieved via a network, forexample, by the sensor module 2200, from global memory included by adatabase, server, and/or other device that will be apparent to a personof skill in the art after having the benefit of this disclosure. Thesensor module 2200 may be operatively connected to the plate module2100, which is discussed in greater detail later in this disclosure.

In one embodiment, the sensor module 2200 may include a sensor toproduce a signal indicative of rotation of the reel. The sensor includedby the sensor module may be the sensor 18 discussed earlier in thisdisclosure, be analogous to sensor 18, or be otherwise provided as willbe appreciated by those of skill in the art. For example, the sensor maydetect an angular orientation in relationship to a reel onto which it isinstalled via being connected to a plate module 2100 installed to areel. The sensor may count rotations of the reel to determine use via achange in the angular orientation sensed by the sensor. In someembodiments, the sensor may include an accelerometer, as discussed abovealong with the examples for the sensor 18. In additional embodiments,the sensor may detect additional conditions, for example, magneticproperties, motion, movement, position, time, use, and othercharacteristics. The sensor may be provided by a fusion sensor, whichmay include features of an accelerometer, gyrometer, gyroscope,magnetometer, and/or other sensors that would be apparent to a person ofskill in the art after having the benefit of this disclosure.

The sensor module 2200 may include a controller or other computerizedcomponents. For example, the sensor module 2200 may include a sensormodule processor operably receiving the signal from the sensor andcounting cumulative forward rotations of the reel. Skilled artisans willappreciate that the sensor module processor may be the first processor10 discussed earlier in this disclosure, analogous to same, or otherwiseprovided, without limitation. The sensor module may additionally includesensor module memory operably associated with the sensor moduleprocessor for storing memory contents comprising the cumulative forwardrotations of the reel. Skilled artisans will appreciate that the sensormodule memory may be the memory 14 discussed earlier in this disclosureor analogous to same.

The sensor module 2200 may include a radio frequency transmitter tocommunicate at least part of the sensor module memory contents, forexample, via a network. Skilled artisans will appreciate that the sensorradio frequency transmitter may be analogous to the communication module28 discussed earlier in this disclosure or analogous to same.

The sensor module 2200 may include an indicator 2240, which may providea visual indication to a user regarding a status of the sensor module2200, a reel associated with a plate module 2100, or another aspect ofoperation that would be appreciated by a person of skill in the artafter having the benefit of this disclosure. In some embodiments, theindicator 2240 may be provided by, or be analogous to, the indicator 26described earlier in this disclosure. In various embodiments, theindicator 2400 may provide a visual indication via one or more of LEDs,e-ink displays, LCD panels, displays, monitors, text readouts, soundalerts, and otherwise as would be appreciated by those of skill in theart.

The sensor module 2200 may include a sensor module battery 2230 poweringat least the sensor module processor, the sensor module memory, thesensor, and the radio frequency transmitter. Those of skill in the artwill appreciate that the sensor module battery 2230 may be analogous tothe battery discussed above and/or otherwise provided, withoutlimitation. In some embodiments, the battery may be rechargeable. A USBor other charging connection may be provided by the sensor module 2200,plate module 2100, or otherwise to supply power to the electroniccomponents and/or battery discussed throughout this disclosure.

The sensor module 2200 may additionally include sensor module powercomponents to manage the charge and discharge of a battery and deliverelectrical power to one or more of the components included by a systemenabled by this disclosure. Those of skill in the art will appreciatethat the sensor module power components may be the power supply module22 discussed earlier in this disclosure or analogous to same.

The sensor module 2200 may include a sensor module enclosure 2250 thatmay include one or more features to facilitate installation to a reel,for example via removable installation to a plate module 2100. Thesensor module enclosure 2250 may include a sensor module dockinginterface 2254 to facilitate the removable installation of the sensormodule 2200 to the plate module 2100 or other device, as will beappreciated by a person of skill in the art after having the benefit ofthis disclosure. For example, the sensor module docking interface 2254may include one or more channels or recesses of material to acceptmaterial from the plate module 2100 or another component. The recess ofmaterial may be configured to receive the distal end of extensionsincluded by a plate module 2100 and may hold the sensor module 2200 tothe plate module 2100 when installed to the plate module 2100. In oneembodiment, the sensor module docking interface 2254 may be providedsuch that it may receive a sensor plate module docking interface 2154,such as may be provided in a slide-and-lock docking operation.

The sensor module enclosure 2250 may additionally include features toassist with maintaining the installation status of the sensor module2200 to the plate module 2100, for example as may be provided by asensor module docking clip receiver 2256. In this example, once a sensormodule 2200 is installed to the plate module 2100, the sensor module2200 may be held in place at least partially by the plate module dockingclip 2156 engaging the sensor module docking clip receiver 2256. Toremove the sensor module 2200 from the plate module 2200, an operatormay engage the plate module docking clip 2156 to disengage from thesensor module docking clip receiver 2256 such that the sensor module2200 may be removable from its docked position on the plate module 2100.Skilled artisans will appreciate additional locking mechanisms that maybe included by the sensor module 2200 and/or the plate module 2100 afterhaving the benefit of this disclosure, which are also intended to beincluded within the scope and spirit of this disclosure.

In one embodiment, the sensor module enclosure 2250 may be provided inmultiple members. For example, the sensor module enclosure 2250 may beprovided by a bottom sensor module enclosure member 2260 and a topsensor module enclosure member 2280. For example, the top sensor moduleenclosure member 2280 may be installable to the bottom sensor moduleenclosure member 2260 to provide a substantially unitary sensor moduleenclosure 2250. An example of a sensor module enclosure 2250 includingmultiple members will be discussed below without limitation.

The complete sensor module enclosure 2250 may include a bottom sensormodule enclosure member 2260. In one example, the bottom sensor moduleenclosure member 2260 may be constructed having a bottom sensor moduleenclosure member body featuring material extending from a bottom sensormodule enclosure member outer surface to a bottom sensor moduleenclosure member inner surface. One or more apertures may be providedpassing through the bottom sensor module enclosure member body, forexample to facilitate connection of the bottom sensor module enclosuremember 2260 to the top sensor module enclosure member 2280, and/or otherconnections that would be appreciated by those of skill in the art afterhaving the benefit of this disclosure.

For example, one or more bottom sensor module enclosure memberconnection apertures 2268 may be provided by the bottom sensor moduleenclosure member 2260 to facilitate installation of the bottom sensormodule enclosure member 2260 to the top sensor module enclosure member2280. In this example, the bottom sensor module enclosure memberconnection apertures 2268 may be aligned with corresponding top sensormodule enclosure member connection receptacles 2268. In this example, ascrew or other hardware may be passed through the bottom sensor moduleenclosure member connection aperture 2268 from a bottom sensor moduleenclosure member outer surface, through the bottom sensor moduleenclosure member body, and exiting the bottom sensor module enclosuremember inner surface such that it may be received by a top sensor moduleenclosure member connection receptacle 2268, without limitation.

The sensor module enclosure 2250 may include a top sensor moduleenclosure member 2280. In one example, the top sensor module enclosuremember 2280 may be constructed having a top sensor module enclosuremember body featuring material extending from a top sensor moduleenclosure member outer surface to a top sensor module enclosure memberinner surface. One or more top sensor module enclosure member connectionreceptacle may be provided to receive a screw or other hardware passedthrough the bottom sensor module enclosure member connection aperture2268, for example to facilitate connection of the bottom sensor moduleenclosure member 2260 to the top sensor module enclosure member 2280and/or other connections that would be appreciated by those of skill inthe art after having the benefit of this disclosure.

In one example, one or more top sensor module enclosure memberconnection receptacle may be provided by the top sensor module enclosuremember 2280 to facilitate installation of the bottom sensor moduleenclosure member 2260 to the top sensor module enclosure member 2280. Inthis example, the bottom sensor module enclosure member connectionapertures 2268 may be aligned with corresponding top sensor moduleenclosure member connection receptacles.

In this example, a screw or other hardware may be passed through thebottom sensor module enclosure member connection aperture 2268, suchthat it may be received by a top sensor module enclosure memberconnection receptacle through the top sensor module enclosure memberouter surface, without limitation. Those of skill in the art willappreciate additional arrangements of connection apertures andconnection receptacles, for example wherein the top sensor moduleenclosure member 2280 include top sensor module enclosure member 2280connection apertures and the bottom sensor module enclosure member 2260includes bottom sensor module enclosure member connection receptacles,without limitation.

A docking interface may be provided to assist removably installing thesensor module 2200 to the plate module 2100. The docking interface mayinclude a plate docking interface 2154 provided by the plate module 2100and a sensor docking interface 2254 provided by the sensor module 2200.The sensor docking interface 2254 may be removably received by the platedocking interface 2154 to provide a docked physical connection. Toremove the sensor module 2200 from the docked physical connection withthe plate module 2100, the sensor module 2200 may be slid, lifted,removed, unclipped, or otherwise disconnected from the plate module 2100to remove the sensor docking interface from the plate docking interface,without limitation.

The plate module 2100 and the sensor module 2200 may include aspects ofan electronic interface to facilitate electronic communication by aphysical connection, wireless connection, and/or otherwise. In someembodiments, electrical power may be supplied through at least part ofthe electronic interface, for example and without limitation, from thebattery of the sensor module 2200 to the plate module 2100.

The electronic interface may include a plate module electronic interfaceand a sensor module electronic interface. When the sensor module 2200 isconfigured in the docked physical connection with the plate module 2100,the plate module electronic interface 2118 may align with the sensormodule electronic interface 2218 to create a docked electronicconnection, for example, by physical contact of conductors. In oneembodiment, the electronic connection may be provided by engagement ofpogo pins or other electrical contacts that would be appreciated by aperson of skill in the art after having the benefit of this disclosure.When in the docked electronic connection, electronic signals may beselectively communicated via the electronic interface.

While docked, a reel identification index associated with a reel ontowhich the plate module 2100 is installed may be communicated from theplate module 2100 to the sensor module 2200 via the electronicinterface. The sensor module 2200 may then use this reel identificationindex to retrieve information about the reel to initialize the analyticand material tracking operations. Information about a reel may beprovided by the plate module 2100, data stored in memory by the sensormodule 2200, retrieved from a network-connected database, or provided inanother way that you be apparent to a person of skill in the art afterhaving the benefit of this disclosure.

In one example, a sensor module 2200 may retrieve a length value for thelength of the material included by the reel identified by the reelidentification index. As material is drawn from the reel, the sensormodule 2200 connected to the plate module 2100 and installed to the reelmay determine the cumulative forward rotations of the reel occurringsubsequent to retrieving the length value. The cumulative forwardrotations may be determined as the difference between the number offorward rotations and the number of revers rotations, withoutlimitation. The sensor module 2200 may analyze the cumulative forwardrotations to determine the length of the material drawn from the reel.The sensor module 2200 may then update the length value identified bythe reel identification index to reflect the length of the materialremaining on the reel after at least part of the material is drawn fromthe reel.

This update may change and/or supplement values stored by the memory ofthe sensor module 2200, plate module 2100 (in embodiments wherein memoryis included by the plate module), or in a network-connected database viathe radio frequency transmitter. In one example, the sensor module maybe connected to a server and/or database over a network. The serverand/or database may provide a global memory accessible over the networkvia the radio frequency transmitter to communicate at least the reelidentification index and the length value. Initial values andinformation regarding the reel may additionally be accessed andretrieved from the global memory. For example, length values associatedwith one or more corresponding reel may be stored by the global memory.The sensor module 2200 may be permitted to access and retrieve thelength value from the global memory as associated with the reelidentification index provided by the plate module 2100. After the drawof material from a reel occurs, length values and/or changes in lengthvalues may be updated in the global memory, such as provided by anetwork communication from the sensor module 2200. Length values storedby the global memory may be displayed to a user via an interface, suchas my be provided on a computer, web browser, SaaS platform,application, or otherwise as would be appreciated by a person of skillin the art after having the benefit of this disclosure.

In one embodiment, the sensor module 2200 may further include a clockthat outputs time values. The sensor module memory may store time seriesdata relative to the cumulative forward rotations of the reel correlatedwith the time values. The sensor module 2200 may additionally include asensor location receiver that outputs a geographic position. The sensormodule 2200 may advantageously associate an event in which the materialis drawn from the reel with the geographic position at which thematerial is drawn, providing additional resolution to users about theuse of a system enabled by this disclosure. This information may befurther interpreted to give useful information such as length ofmaterial drawn from a reel, the location at which material was drawn,the amount of material drawn at a location, time stamps, draw rates, andother information. By analyzing the information provided by a systemenabled by this disclosure, a processor connected to the global memorymay recommend a reel for an anticipated job having sufficient materialavailable while minimizing waste that may be cause by leaving an unknownor unusable amount of material on the reel after a job is complete.

In some embodiments, the plate module may be sold or otherwise providedto customers as a stand-alone product. The plate module may be installedto a reel, spool, or other device without requiring a sensor to beattached at the time of installation, storage, movement, relocation, orother times. Essentially, in this embodiment, the plate module may beintended to remain with the reel as it holds material to be drawn fromit. The sensor module may then be temporarily installed to the platemodule while material is drawn from reel onto which the plate module isinstalled to gather data regarding the draw event and communicate suchdata to server to update a global inventory. The sensor module may thenbe removed from the plate module once the draw event is complete. Theseplate modules may include features to be read by sensor modules, sensordevices, readers, smartphone applications, or otherwise even if thesensor module is not attached. Such features may include RFID, QR codes,NFC, Bluetooth, and/or other communication protocols that would beappreciated by a person of skill in the art after having the benefit ofthis disclosure. Information that may be read from the plate module mayassist with identifying the reel, the material remaining on the reel,properties of the material on the reel, location, last use, and otherinformation that would be apparent to skilled artisans.

While various aspects have been described in the above disclosure, thedescription of this disclosure is intended to illustrate and not limitthe scope of the invention. The invention is defined by the scope of theappended claims and not the illustrations and examples provided in theabove disclosure. Skilled artisans will appreciate additional aspects ofthe invention, which may be realized in alternative embodiments, afterhaving the benefit of the above disclosure. Other aspects, advantages,embodiments, and modifications are within the scope of the followingclaims.

What is claimed is:
 1. A system for tracking a length of a materialwound on a reel, the material having a known starting length and a knownthickness, the reel having a reel core of known width and known volume,the reel further having reel flanges physically connected to the reel atopposite ends of the reel core such that the reel flanges rotate withthe reel core, the material being wound about the reel core between thereel flanges, the system comprising: a plate module to be physicallyinstalled to the reel comprising a reel identification index to identifythe reel; a sensor module removably installed to the plate modulecomprising: a sensor to produce a signal indicative of rotation of thereel, a sensor module processor operably receiving the signal from thesensor and counting cumulative forward rotations of the reel, a sensormodule memory operably associated with the sensor module processor forstoring memory contents comprising the cumulative forward rotations ofthe reel, a radio frequency transmitter to communicate at least part ofthe sensor module memory contents, and a sensor module battery poweringat least the sensor module processor, the sensor module memory, thesensor, and the radio frequency transmitter; and wherein a remaininglength of the material wound on the reel is calculated based on at leastthe cumulative forward rotations of the reel.
 2. The system of claim 1,further comprising: a docking interface comprising: a plate dockinginterface provided by the plate module, and a sensor docking interfaceprovided by the sensor module; wherein the sensor docking interface isremovably received by the plate docking interface to provide a dockedphysical connection; and wherein the docked physical connection isselectively disengaged to remove the sensor module from the platemodule.
 3. The system of claim 2: an electronic interface comprising: aplate module electronic interface, and a sensor module electronicinterface; wherein the docked physical connection aligns the platemodule electronic interface and the sensor module electronic interfaceto create a docked electronic connection; and wherein electronic signalsare selectively communicated via the electronic interface in the dockedelectronic connection.
 4. The system of claim 3, wherein the platemodule is at least partially powered by the sensor module battery viathe electronic interface.
 5. The system of claim 3, wherein the reelidentification index is communicated from the plate module to the sensormodule via the electronic interface.
 6. The system of claim 1: whereinthe sensor module retrieves a length value for the length of thematerial included by the reel identified by the reel identificationindex; wherein the sensor module determines the cumulative forwardrotations of the reel occurring subsequent to retrieving the lengthvalue; wherein the sensor module analyzes the cumulative forwardrotations to determine the length of the material drawn from the reel;and wherein the sensor module updates the length value identified by thereel identification index to reflect the length of the materialremaining on the reel after at least part of the material is drawn fromthe reel.
 7. The system of claim 6, further comprising: a global memoryaccessible over a network via the radio frequency transmitter tocommunicate at least the reel identification index and the length value;wherein one or more length values associated with respectively one ormore corresponding reels are stored by the global memory; and wherein atleast part of the one or more length values stored by the global memoryare displayed to a user via an interface.
 8. The system of claim 1,wherein the sensor module further comprises: a clock that outputs timevalues, the sensor module memory storing time series data indicative ofthe cumulative forward rotations of the reel correlated with the timevalues.
 9. The system of claim 1, wherein the sensor module furthercomprises: a sensor location receiver that outputs a geographicposition; wherein the sensor module associates an event in which thematerial is drawn from the reel with the geographic position at whichthe material is drawn; wherein the sensor module stores the geographicposition associated with the event in the sensor module memory.
 10. Thesystem of claim 1, wherein the sensor module further comprises: a sensorlocation receiver that outputs a geographic position; a clock thatoutputs time values, the sensor module memory storing time series dataindicative of the cumulative forward rotations of the reel correlatedwith the time values; wherein the sensor module associates the timeseries data indicative of an event in which the material is removed fromthe reel with the geographic position at which the event occurred;wherein the sensor module processor further stores the time series dataindicative of the geographic position associated with the event in thesensor module memory.
 11. The system of claim 1, wherein the sensordetects an angular orientation.
 12. The system of claim 11, wherein therotations of the reel are determined using a change in the angularorientation sensed by the sensor.
 13. The system of claim 1, wherein thesensor comprises an accelerometer.
 14. A system for tracking a length ofa material wound on a reel, the material having a known starting lengthand a known thickness, the reel having a reel core of known width andknown volume, the reel further having reel flanges physically connectedto the reel at opposite ends of the reel core such that the reel flangesrotate with the reel core, the material being wound about the reel corebetween the reel flanges, the system comprising: a plate module to bephysically installed to the reel comprising a reel identification indexto identify the reel; a sensor module removably installed to the platemodule comprising: a sensor to detect change in angular orientation andproduce a signal indicative of rotation of the reel, a sensor moduleprocessor operably receiving the signal from the sensor and countingcumulative forward rotations of the reel, a sensor module memoryoperably associated with the sensor module processor for storing memorycontents comprising the cumulative forward rotations of the reel, and asensor module battery powering at least the sensor module processor, thesensor module memory, and the sensor; and a docking interfacecomprising: a plate docking interface provided by the plate module, asensor docking interface provided by the sensor module, wherein thesensor docking interface is removably received by the plate dockinginterface to provide a docked physical connection, and wherein thedocked physical connection is selectively disengaged to remove thesensor module from the plate module; an electronic interface comprising:a plate module electronic interface, and a sensor module electronicinterface, wherein the docked physical connection aligns the platemodule electronic interface and the sensor module electronic interfaceto create a docked electronic connection, wherein electronic signals areselectively communicated via the electronic interface in the dockedelectronic connection, and wherein the reel identification index iscommunicated from the plate module to the sensor module via theelectronic interface; wherein a remaining length of the material woundon the reel is calculated based on at least the cumulative forwardrotations of the reel; wherein the sensor module retrieves a lengthvalue for the length of the material included by the reel identified bythe reel identification index; wherein the sensor module determines thecumulative forward rotations of the reel occurring subsequent toretrieving the length value; wherein the sensor module analyzes thecumulative forward rotations to determine the length of the materialdrawn from the reel; and wherein the sensor module updates the lengthvalue identified by the reel identification index to reflect the lengthof the material remaining on the reel after at least part of thematerial is drawn from the reel.
 15. The system of claim 14, furthercomprising: a global memory accessible over a network via radiofrequency transmitter to communicate at least the reel identificationindex and the length value; and wherein one or more length valuesassociated with respectively one or more corresponding reels are storedby the global memory.
 16. The system of claim 14, wherein the sensormodule further comprises: a clock that outputs time values, the sensormodule memory storing time series data indicative of the cumulativeforward rotations of the reel correlated with the time values.
 17. Thesystem of claim 14, wherein the sensor module further comprises: asensor location receiver that outputs a geographic position; wherein thesensor module associates an event in which the material is drawn fromthe reel with the geographic position at which the material is drawn;wherein the sensor module stores the geographic position associated withthe event in the sensor module memory.
 18. A method for tracking alength of a material wound on a reel, the material having a knownstarting length and a known thickness, the reel having a reel core ofknown width and known volume, the reel further having reel flangesphysically connected to the reel at opposite ends of the reel core suchthat the reel flanges rotate with the reel core, the material beingwound about the reel core between the reel flanges, the methodcomprising: a) physically installing a plate module to the reel, theplate module comprising a reel identification index to identify thereel; b) removably installing a sensor module to the plate module; c)producing a signal indicative of rotation of the reel using a sensorincluded by the sensor module; d) counting cumulative forward rotationsof the reel via a sensor module processor using at least the signal; e)storing memory contents comprising the cumulative forward rotations ofthe reel to a sensor module memory operably associated with the sensormodule processor; and f) calculating a remaining length of the materialwound on the reel based on at least the cumulative forward rotations ofthe reel.
 19. The method of claim 18, further comprising: g) providing adocked physical connection via receiving a sensor docking interface ofthe sensor module by a plate docking interface of the plate module toprovide a docked physical connection, the docked physical connectionbeing selectively disengaged to remove the sensor module from the platemodule; and h) aligning a plate module electronic interface of the platemodule and a sensor module electronic interface of the sensor module tocreate an electronic interface, wherein electronic signals areselectively communicated via the electronic interface.
 20. The method ofclaim 18, further comprising: i) retrieving a length value via thesensor module for the length of the material included by the reelidentified by the reel identification index; j) determining via thesensor module the cumulative forward rotations of the reel occurringsubsequent to retrieving the length value; k) analyzing via the sensormodule the cumulative forward rotations to determine the length of thematerial drawn from the reel; and l) updating via the sensor module thelength value identified by the reel identification index to reflect thelength of the material remaining on the reel after at least part of thematerial is drawn from the reel.